Text preview for : KP-46WT520.pdf part of Sony KP-46WT520 154 page service manual (Jul-2004) for Sony 46, 51 & 57 inch rear video projection color TV (NTSC) model #'s KP-46WT520, KP-51WS520 & KP-57WS520 with AX-1X chassis.



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HISTORY INFORMATION FOR THE FOLLOWING MANUAL:

SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION

AX-1X
CHASSIS NO.

CHASSIS

KP-46WT520 KP-51WS520 KP-57WS520

RM-Y916

US/CND/MX

SCC-M37B-A

RM-Y916

US/CND/MX

SCC-M37C-A

RM-Y916

US/CND/MX

SCC-M37A-A

ORIGINAL MANUAL ISSUE DATE: 7/2004
:UPDATED ITEM
REVISION DATE 7/2004 10/2004 SUBJECT No revisions or updates are applicable at this time. Corrected 1-9. Speaker Grille, HA1 Board, and HB2 Board Removal (KP-46WT520 Only) to show correct location of HB2 Board. Replaced Page 14 with Page 14 Removed Note from section 2-12-1. Setup For Adjustment. Note is intended for use by the factory during production, and should not be performed by service technicians. Replaced Page 50 with Page 50 Corrected PN for AC Power Cord for KP-51WS520/57WS520 Models. Replaced Page 104 with Page 104 Corrected PN for Resistor Bridge on A Board Replaced Page 127 with Page 127 Updated Table of Contents (Replaced Page 3 with Page 3) Added Caution statement (Replaced Page 5 with Page 5) BH Board introduced due to design change. Added BH Board Removal to Disassembly section (Replaced Page 12 with Page 12) Added BH Board Schematics, PWBs, Exploded View, and Electrical Parts List (Added Pages 93-A through 93-C, Replaced Pages 148-150 with Pages 148-157) Corrected PN for Bottom Cabinet (46) Assy, Corrected/removed items included in Speaker Grill Assembies (Replaced Page 102 & 103 with Page 102 & 103) Added BH Board and A Board (Replaced Page 104 with Page 104) New CRT Coupler Assemblies & Shades introduced for KP-46WT520/51WS520 Affects SNs 8,500,001 and up (Replaced Page 105 with Page 105) Added A Board differences to Electrical Parts List (Replaced Page 111 and 118 with 111 and 118) Corrected position of CRT Couplers and Shades (Replaced Page 105 with 105)

12/2004 12/2004 2/2005

8/2005

COLOR REAR VIDEO PROJECTION
9-965-968-06

Self Diagnosis

Supported model

SERVICE MANUAL
MODEL NAME REMOTE COMMANDER DESTINATION

AX-1X
CHASSIS NO.

CHASSIS

KP-46WT520 KP-51WS520 KP-57WS520

RM-Y916

US/CND/MX

SCC-M37B-A

RM-Y916

US/CND/MX

SCC-M37C-A

RM-Y916

US/CND/MX

SCC-M37A-A

KP-51WS520

RM-Y916

COLOR REAR VIDEO PROJECTION
9-965-968-06

KP-46WT520/51WS520/57WS520

TABLE OF CONTENTS
SECTION TITLE PAGE Specifications ................................................................................. 4 Warnings and Cautions .................................................................. 5 Safety Check-Out ........................................................................... 6 Self-Diagnostic Function................................................................. 7 SECTION 1: DISASSEMBLY ............................................................... 10 1-1. Rear Board Removal............................................................ 10 1-2. Chassis Assembly Removal ................................................. 10 1-3. Service Position ....................................................................11 1-4. Terminal Board and P Board Removal ..................................11 1-5. BM Board or BH Board Removal ......................................... 12 1-6. A Board, D Board, and G Board Removal............................ 12 1-7. High-Voltage Cable Installation and Removal ...................... 13 1-8. Picture Tube Removal .......................................................... 13 1-9. Speaker Grille, HA1 Board, and HB2 Board Removal (KP-46WT520 Only) ............................................................. 14 1-10. Speaker Grille, HA1 Board, and HB1 Board Removal (KP-51WS520/57WS520 Only) ............................................ 14 1-11. Beznet Assembly Removal .................................................. 15 1-11-1. Screen Tape Method................................................ 15 1-12. SR Board Removal .............................................................. 16 Wire Dressing ............................................................................... 17 SECTION 2: SET-UP ADJUSTMENTS................................................ 31 2-1. Screen Voltage Adjustment (G2) (Coarse Adjustment) ........ 31 2-2. Screen (G2) Adjustment (Fine Adjustment).......................... 31 2-3. Deflection Yoke Tilt Adjustment ............................................ 31 2-4. Focus Lens Adjustment ........................................................ 32 2-5. Focus VR Adjustment........................................................... 32 2-6. Centering Magnet Adjustment .............................................. 33 2-7. 2-Pole Magnet Adjustment .................................................. 33 2-8. 4-Pole Magnet Adjustment ................................................... 33 2-9. Defocus Adjustment (Blue)................................................... 33 2-10. Electrical Adjustments by Remote Commander ................... 34 2-10-1. Method of Entering the Service Adjustment Mode .. 34 2-10-2. Memory Write Confirmation Method ........................ 34 2-10-3. Adjusting Buttons and Indicator ............................... 34 2-11. Adjustable Service Data Lists .............................................. 35 2-11-1. ID Map Table............................................................ 49 2-12. Registration Adjustment (PJE Mode Only) ........................... 50 2-12-1. Setup for Adjustment ............................................... 50 2-12-2. Main Deflection Adjustment ..................................... 50 2-12-3. Operation Method for Projector Engine Mode ......... 51 2-13. PJE Adjustment (Sub Deflection Adjustment) ...................... 52 2-13-1. Adjustment for NTSC Full Mode .............................. 53 2-13-2. Copying All Registration Data to Other Modes ........ 55 2-14. Auto Registration Offsets ..................................................... 55 2-15. Auto Registration Error Codes ............................................. 56 2-16. Auto Registration Diagnostics .............................................. 57 SECTION 3: SAFETY-RELATED ADJUSTMENTS............................. 58 D BOARD ..................................................................................... 58 3-1. HV Regulation Circuit Check and Adjustment ...................... 58 3-2. HV Hold Down Circuit Operation Check .............................. 58 G BOARD ..................................................................................... 59 3-3. +B Max Voltage Confirmation .............................................. 59 3-4. +B OVP Confirmation ........................................................... 59 SECTION TITLE PAGE SECTION 4: CIRCUIT ADJUSTMENTS .............................................. 60 4-1. P & P Sub Contrast Adjustment (Video) (SCON) ................. 60 4-2. P & P Sub Contrast Adjustment (RF) (SCON) ..................... 60 4-3. P & P Sub-Hue and Sub-Color Adjustment Video (SHUE, SCOL) ..................................................................... 60 4-4. P & P Sub-Hue and Sub-Color Adjustment (RF) (SHUE, SCOL) ..................................................................... 60 4-5. Blue Offset Adjustment ....................................................... 61 SECTION 5: DIAGRAMS ..................................................................... 62 5-1. Circuit Boards Location ........................................................ 62 5-2. Printed Wiring Boards and Schematic Diagrams Information ......................................... 62 5-3. Block Diagrams .................................................................... 64 Signal Flow Block Diagram .................................................. 64 Power Block Diagram........................................................... 65 Audio Signal Path Block Diagram ........................................ 66 Video Path Block Diagram ................................................... 67 SYNC/OSD Path Block Diagram.......................................... 68 5-4. Schematics and Supporting Information ............................. 69 CR Board Schematic Diagram ............................................ 69 CB Board Schematic Diagram ............................................ 70 CG Board Schematic Diagram ............................................ 71 VM Board Schematic Diagram ............................................ 74 A Board Schematic Diagram (1 of 6).................................... 75 A Board Schematic Diagram (2 of 6).................................... 76 A Board Schematic Diagram (3 of 6).................................... 77 A Board Schematic Diagram (4 of 6).................................... 78 A Board Schematic Diagram (5 of 6).................................... 79 A Board Schematic Diagram (6 of 6).................................... 80 D Board Schematic Diagram (1 of 2) ................................... 85 D Board Schematic Diagram (2 of 2) ................................... 86 BM Board Schematic Diagram (1 of 3) ................................ 90 BM Board Schematic Diagram (2 of 3) ................................ 91 BM Board Schematic Diagram (3 of 3) ................................ 92 BH Board Schematic Diagram (1 of 2) .............................. 93-A BH Board Schematic Diagram (2 of 2) ..............................93-B G Board Schematic Diagram ............................................... 94 HA1 Board Schematic Diagram .......................................... 97 P Board Schematic Diagram ................................................ 98 SR Board Schematic Diagram ............................................ 99 HB1 Board Schematic Diagram (KP-51WS520/57WS520 Only) .............................. 99 HB2 Board Schematic Diagram (KP-46WT520 Only) .......... 99 5-5. Semiconductors ................................................................. 101 SECTION 6: EXPLODED VIEWS ...................................................... 102 6-1. Cover (KP-46WT520 Only) ................................................ 102 6-2. Cover (KP-51WS520/57WS520 Only) ............................... 103 6-3. Chassis .............................................................................. 104 6-4. Picture Tube ....................................................................... 105 SECTION 7: ELECTRICAL PARTS LIST .......................................... 106

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KP-46WT520/51WS520/57WS520

SPECIFICATIONS
Power Requirements 120V AC, 60Hz Power Consumption (W) In Use (Max) 235W In Standby Under 1 W Inputs/Outputs HDMI IN Video 1080i, 720p, 480p, 480i Audio Two channel linear PCM 32, 44.1, and 48 kHz, 16, 20, and 24 bit Video (IN) 4 total (1 on front panel) 1Vp-p, 75ohms unbalanced, sync negative S Video (IN) 3 total (1 on front panel) Y: 1Vp-p, 75ohms unbalanced, sync negative C: 0.286Vp-p (Burst signal), 75ohms Audio (IN) 7 total (1 on front panel) 500 mVrms (100% modulation) Impedance:47 kilohm Component Video Input 2 ( Y,PB,PR) Y: 1.0 Vp-p, 75 ohms unbalanced, sync negative; PB: 0.7 Vp-p, 75 ohms; PR: 0.7 Vp-p, 75 ohms Control S (IN/OUT) 1 total Variable/Fixed Audio (OUT) More than 408 m Vrms at the maximum volume setting (Variable) More than 408 m Vrms (Fixed) Impedance (output):2 kilohms

KP-46WT520 Speaker Output (W) Dimensions (W x H x D) mm in Mass kg lbs

KP-51WS520 20W x 2

KP-57WS520

1086 x 1017 x 609 mm 423/4 x 40 x 24 in 61.3 kg 135 lbs

1194 x 1280 x 666 mm 47 x 501/2 x 261/4 in 77.2 kg 170 lbs

1326 x 1377 x 692 mm 521/4 x 541/4 x 271/4 in 88 kg 194 lbs

Projection System
3 picture tubes, 3 lenses, horizontal in-line system

Screen Size (measured diagonally)
46 inches (KP-46WT520) 51 inches (KP-51WS520) 57 inches (KP-57WS520)

Picture Tube
7-inch high-brightness monochrome tubes (6.3 raster size), with optical coupling and liquid cooling system.

Supplied Accessories
Remote Control RM-Y916 Batteries (2) size AA (R6)

Projection Lenses
High performance, large diameter hybrid lens F1.1

Optional Accessories Antenna
75 ohm external terminal for VHF/UHF A/V Cable (VMC-810/820/830 HG) Audio Cable (RKC-515HG) Component Video Cable (VMC-10/30 HG) Control S Cable (RK-G69HG) TV Stand SU-46WT11 (For KP-46WT520 Only)

Television System
NTSC, American TV Standard

Channel Coverage
VHF: 2-13/UHF: 14-69/CATV: 1-125

Design and specifications are subject to change without notice.

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KP-46WT520/51WS520/57WS520

WARNINGS AND CAUTIONS

CAUTION
instructions are for use qualified service personnel To the of These servicingthan that contained in thebyoperating instructions unless only.are reduceed to riskso.electric shock, do not perform any servicing other you qualifi do

WARNING!!
An isolation transformer should be used during any service to avoid possible shock hazard, because of live chassis. The chassis of this receiver is directly connected to the ac power line.

! SAFETY-RELATED COMPONENT WARNING!!
Components identified by shading and ! mark on the schematic diagrams, exploded views, and in the parts list are critical for safe operation. Replace these components with Sony parts whose part numbers appear as shown in this manual or in supplements published by Sony. Circuit adjustments that are critical for safe operation are identified in this manual. Follow these procedures whenever critical components are replaced or improper operation is suspected.

ATTENTION!!
instructions de service sont à personnel de service Pour le risque Ces faire l'entretien autre que celuil'usage dudans le Mode d'emploi qualifié seulement.soyez prévenirfaire ainsi.de choc électrique, ne pas contenu à moins que vous qualifié

Afin d'eviter tout risque d'electrocution provenant d'un chássis sous tension, un transformateur d'isolement doit etre utilisé lors de tout dépannage. Le chássis de ce récepteur est directement raccordé à l'alimentation du secteur.

! ATTENTION AUX COMPOSANTS RELATIFS A LA SECURITE!!
Les composants identifies par une trame et par une marque ! sur les schemas de principe, les vues explosees et les listes de pieces sont d'une importance critique pour la securite du fonctionnement. Ne les remplacer que par des composants Sony dont le numero de piece est indique dans le present manuel ou dans des supplements publies par Sony. Les reglages de circuit dont l'importance est critique pour la securite du fonctionnement sont identifies dans le present manuel. Suivre ces procedures lors de chaque remplacement de composants critiques, ou lorsqu'un mauvais fonctionnement suspecte.

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KP-46WT520/51WS520/57WS520

SAFETY CHECK-OUT
After correcting the original service problem, perform the following safety checks before releasing the set to the customer: 1. Check the area of your repair for unsoldered or poorly soldered connections. Check the entire board surface for solder splashes and bridges. 2. Check the interboard wiring to ensure that no wires are "pinched" or touching high-wattage resistors. 3. Check that all control knobs, shields, covers, ground straps, and mounting hardware have been replaced. Be absolutely certain that you have replaced all the insulators. 4. Look for unauthorized replacement parts, particularly transistors, that were installed during a previous repair. Point them out to the customer and recommend their replacement. 5. Look for parts which, though functioning, show obvious signs of deterioration. Point them out to the customer and recommend their replacement. 6. Check the line cords for cracks and abrasion. Recommend the replacement of any such line cord to the customer. 7. Check the B+ and HV to see if they are specified values. Make sure your instruments are accurate; be suspicious of your HV meter if sets always have low HV. 8. Check the antenna terminals, metal trim, "metallized" knobs, screws, and all other exposed metal parts for AC leakage. Check leakage as described below. Leakage Test The AC leakage from any exposed metal part to earth ground and from all exposed metal parts to any exposed metal part having a return to chassis, must not exceed 0.5 mA (500 microamperes). Leakage current can be measured by any one of three methods. 1. A commercial leakage tester, such as the Simpson 229 or RCA WT-540A. Follow the manufacturers' instructions to use these instructions. 2. A battery-operated AC milliammeter. The Data Precision 245 digital multimeter is suitable for this job. 3. Measuring the voltage drop across a resistor by means of a VOM or battery-operated AC voltmeter. The "limit" indication is 0.75 V, so analog meters must have an accurate low voltage scale. The Simpson's 250 and Sanwa SH-63TRD are examples of passive VOMs that are suitable. Nearly all battery-operated digital multimeters that have a 2 VAC range are suitable (see Figure A).

How to Find a Good Earth Ground A cold-water pipe is a guaranteed earth ground; the cover-plate retaining screw on most AC outlet boxes is also at earth ground. If the retaining screw is to be used as your earth ground, verify that it is at ground by measuring the resistance between it and a cold-water pipe with an ohmmeter. The reading should be zero ohms. If a cold-water pipe is not accessible, connect a 60- to 100-watt troublelight (not a neon lamp) between the hot side of the receptacle and the retaining screw. Try both slots, if necessary, to locate the hot side on the line; the lamp should light at normal brilliance if the screw is at ground potential (see Figure B).

To Exposed Metal Parts on Set
Trouble Light AC Outlet Box Ohmmeter

0.15 µF

1.5 k

AC Voltmeter (0.75 V)
Cold-water Pipe

Earth Ground

Figure A. Using an AC voltmeter to check AC leakage.

Figure B. Checking for earth ground.

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KP-46WT520/51WS520/57WS520

SELF-DIAGNOSTIC FUNCTION

Self Diagnosis

Supported model

The units in this manual contain a self-diagnostic function. If an error occurs, the STANDBY/TIMER LED will automatically begin to flash. The number of times the LED flashes translates to a probable source of the problem. A definition of the STANDBY/TIMER LED flash indicators is listed in the instruction manual for the user's knowledge and reference. If an error symptom cannot be reproduced, the Remote Commander can be used to review the failure occurrence data stored in memory to reveal past problems and how often these problems occur. Diagnostic Test Indicators When an error occurs, the STANDBY/TIMER LED will flash a set number of times to indicate the possible cause of the problem. If there is more than one error, the LED will identify the first of the problem areas. Results for all of the following diagnostic items are displayed on screen. If the screen displays a "0", no error has occurred.
No. of times STANDBY / TIMER lamp flashes Does not light

Diagnostic Item Power does not turn on

Display Result _______

Probable Cause Location · Power cord is not plugged in. · Fuse is burned out (F6000). (G Board) · H.OUT (Q5001) is shorted. (D Board) · +B PWM (Q5201) is shorted. (D Board) · IC6503 is faulty. (D Board) · 15V is not supplied. (D Board) · IC5101 is faulty. (D Board) · · · · ·

Detected Symptoms Power does not come on. No power is supplied to the TV. AC Power supply is faulty. Power does not come on. Load on power line shorted.

+B Overcurrent (OCP)*

2 times

2:0 or 2:1

+B Overvoltage (OVP) Vertical Deflection Stopped

3 times 4 times

3:0 or 3:1 4:0 or 4:1

White Balance Failure (not balanced)

5 times

5:0 or 5:1

LOW +B OCP/OVP (overcurrent/overvoltage)***

6 times

6:0 or 6:1

Horizontal Deflection Stopped Audio Protection

7 times 8 times

7:0 or 7:1 8:0 or 8:1

Zero Crossing Detector HV Protection

9 times 10 times

9:0 or 9:1 10:0 or 10:1

· Video OUT (IC9101, IC9201, IC9301) is faulty. (CR, CG, CB Board) · CRT drive (IC452) is faulty. (A Board) · G2 is improperly adjusted.** · +5 line is overloaded. (A and BM Boards) · +5 line is shorted. (A and BM Boards) · IC303 is faulty. (A Board) · Q5006 is broken (D Board) · IC452 is faulty (A Board) · + or - 22V audio supply is not present--Check PS600 & PS601 · Audio AMP is damaged IC601 on A Board · D6116 or D6301 is open (G Board) · Q8014 or Q8013 have shorted replace along with R8051 on D Board · IC8005 is damaged (D Board)

· Has entered standby mode. · Has entered standby mode after Horizontal raster. · Vertical deflection pulse is stopped. · Power line is shorted or power supply is stopped. · No raster is generated. · CRT cathode current detection reference pulse output is small.

· No picture

· No picture · No picture

· No picture · No picture

* If a +B overcurrent is detected, stoppage of the vertical deflection is detected simultaneously. The symptom that is diagnosed first by the microcontroller is displayed on the screen. ** Refer to Screen (G2) Adjustment (Fine Adjustments) in Section 2 of this manual. *** If STANDBY/STEREO LED flashes six (6) times, unplug the unit and wait 10 seconds before performing the adjustment.

KP-46WT520/51WS520/57WS520

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KP-46WT520/51WS520/57WS520
Display of Standby/Timer LED Flash Count TIMER Indicator

STAND BY Indicator

Diagnostic items +B Overcurrent Low +B Overvoltage Vert. Deflection Stopped White Balance Failure Low +B OCP/OVP Horiz. Deflection Stopped Audio Protection Zero Crossing Detector HV Protection

Flash count 2 times 3 times 4 times 5 times 6 times 7 times 8 times 9 times 10 times

Lamp ON 0.3 sec. Lamp OFF 0.3 sec.

Lamp OFF 3 sec.

Release of TIMER STAND BY indicator blinking The TIMER/STANDBY indicator blinking display is released by turning OFF the power switch on the TV main unit or removing the plug from the power. Self-Diagnosis Screen Displays In cases of malfunctions where it is not possible to determine the symptom such as when the power goes off occasionally or when the screen disappears occasionally, there is a screen display on whether the malfunction occurred or not in the past (and whether the detection circuit operated or not) in order to allow confirmation. Screen Display Method Quickly press the remote command button in the following order from the standby state. Display Channel 5 SELF DIAGNOSIS 2: +B OCP 3: +B OVP 4: VSTOP 5: AKB 6: LOWB 7: H-STOP 8: AUDIO 9: ZCD 10: HV PROT 101: WDT 0 0 0 1 0 0 0 0 0 24 Sound Volume* _ Power ON

*Note that this differs from entering the service mode (sound volume + ) Numeral "0" means that no fault was detected. Numeral "1" means a fault was detected one time only.

Self-Diagnosis Screen Display The results display is not automatically cleared. In case of repairs and after repairs, check the self-diagnosis screen and be sure to return the results display to " 0 ". If the results display is not returned to " 0 " it will not be possible to judge a new malfunction after completing repairs. Method of Clearing Results Display 1. Power off (Set to the stand by mode.) 2. Display Channel 5 Sound Volume + Power ON (Service Mode) 3. Channel 8 ENTER (Test reset = Factory preset condition) Method of Ending Self Diagnosis Screen When ending the self-diagnosis screen completely, turn the power switch OFF on the remote commander or the main unit.

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KP-46WT520/51WS520/57WS520
Self-Diagnosis Function Operation +B overcurrent (OCP) Occurs when excessive current flows through R6812. The increase in voltage across Q6803 causes it to turn on which sends a high signal to the micro. +B overvoltage (OVP) IC6801 detects +B OVP condition and turns on Q6802. This sends a high signal to the micro and also shuts down the AC relay. V-STOP Occurs when an absence of the vertical deflection pulse is detected by pin 56 of IC452 (A Board). Power supply will shut down when waveform interval exceeds 2 seconds. White Balance Failure If the RGB levels* do not balance within 2 seconds after the power is turned on, this error will be detected by IC452 (A Board). TV will stay on, but there will be no picture. *(Refers to the RGB levels of the AKB detection Ref pulse that detects 1K). Low B OCP/OVP Occurs when set 5V is out. Also check for : + 135V line shorted + 135V line is going over 145V Horizontal Deflection Stopped Occurs when either: 1) a +B overcurrent is detected (Q6803), or 2) IC452 (A Board) is damaged. Self-Diagnosis Block Diagram

A
IC702 MAIN MICRO STBY-LED 48 44 45 43 STR STBY-LED OCP OVP LOW B ERR AC RLY 69 1 4 CLKO DATO 28 31 53 52

IC452 Y/C JUNGLE AKB SCL VPROT SDA HPROT 58 56 57

A
CRT VDY-

R5104

R5105

G
RY6000

BM
R5125

5V

P_SW(-) 2 3

Q5018
2 IC5007 14

D
IC6801 Q6802
2

Q451

Q6102

D6803

Q452
D452

1K-PROT2 +B OCP

+B

1 3

A
IC303 5V 2 3 1

D6505

R6812

+BVOP
D453

+B

+B

D
D6805

R6803

+B OCP

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KP-46WT520/51WS520/57WS520

SECTION 1: DISASSEMBLY 1-1. REAR BOARD REMOVAL

2 Rear board

1 10 Screws (KP-46WT520 Only) 13 Screws (KP-51WS520 Only) 12 Screws (KP-57WS520 Only) Dome Washer Hex Tap 4 x 20

1-2. CHASSIS ASSEMBLY REMOVAL

1 Three screws Dome Washer (Hex Tap 4 x 20)

2 Chassis assy

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KP-46WT520/51WS520/57WS520

1-3. SERVICE POSITION

1 Free wiring from purse locks. NOTE: Observe wire dress and return to original condition. 2 Covers Remove covers from chassis assembly with pliers when checking printed circuit boards. After checking, turn the covers over and re-secure them with the screws.

Chassis assembly

Screws (+BVTP 3x12)

1-4. TERMINAL BOARD AND P BOARD REMOVAL
6 Four screws +BVTT 3x8

P board

4 Disconnect Ground Wire and Cable 5 Two screws +BVTT 3 X 8

3 One screw (M3 X 8) P, SW(+)

2 Six screws (+BVTP 3x12) Main bracket Terminal board 1 Two screws Dome Washer Hex Tap 4 x 20

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11

1-5.

KP-46WT520/51WS520/57WS520

BM BOARD OR BH BOARD REMOVAL
3 Pry apart shield to remove BM board

BM board or BH board

1 Pull gently back on clips to release 2

Main bracket

1-6. A BOARD, D BOARD, AND G BOARD REMOVAL
1 Four screws (+BVTP 3x12)

Seven screws 2 (+BVTP 3x12) D board Two screws 3 (+BVTP 3x12)

A board

G board

4 Claws Main bracket

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KP-46WT520/51WS520/57WS520

1-7. HIGH-VOLTAGE CABLE INSTALLATION AND REMOVAL

(1) Removal

(2) Installation Gutter 1 Rubber cap

2 HV cable turn 90

Hook

1 HV cable

1-8. PICTURE TUBE REMOVAL
CAUTION: Removing the arrow-marked screws is strictly prohibited. If removed, it may cause liquid to spill.
4 Four screws

Lens Picture tube

Dome Washer Hex Tap 4x20 5 Lens 6 Shade 10 Four screws (+BVTP 4x12) 11 Picture tube (2 screws for Red Shade 1 screw for Green Shade) (+BVTP 4x12)

2 Four screws (2 per side) Dome Washer Hex Tap 4x20

9 Deflection yoke 8 Neck assy 7 CR board

3

1 Four screws (2 per side) Dome Washer Hex Tap 4x20

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KP-46WT520/51WS520/57WS520

1-9. SPEAKER GRILLE, HA1 BOARD, AND HB2 BOARD REMOVAL (KP-46WT520 ONLY)



Door, side terminal HB2 board

5

4 Two screws (+BVTP3x12)

1 Four screws Dome Washer Hex Tap 4x20 (2 per side)

2 The Speaker Grille Assy Note: After removing the screws pull firmly out (from the bottom) to release it.

3 Four screws (+BVTP 3x12) HA1 board

1-10.SPEAKER GRILLE, HA1 BOARD, AND HB1 BOARD REMOVAL (KP-51WS520/57WS520 ONLY)
HB1 board 6 Two screws (+BVTP 3x12) Input Terminal Plate

5 Input Terminal Bracket Four screws Dome Washer Hex Tap 4 x 20 4 Input Terminal Cover Two screws (+BVTP 3x12) The Speaker Grille Assy Note: The Speaker Grille Assy is securely attached. After removing the screws pull firmly out (from the bottom) then down to release it. 2

1 Six screws Dome Washer Hex Tap 4x20 -3 per side (KP-51WS520/57WS520 Only)

2

3 Four screws (+BVTP 3x12) HA1 board

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KP-46WT520/51WS520/57WS520

1-11.BEZNET ASSEMBLY REMOVAL
Eight screws (KP-46WT520 Only) Nine screws (KP-51WS520/57WS520 Only) Dome Washer Hex Tap 4x20

3

Beznet assy

2 Four screws Dome Washer Hex Tap 4x20 -2 per side

4 Four screws Dome Washer Hex Tap 4x20 1 Six screws Dome Washer Hex Tap 4x20 -3 per side (KP-46WT520 Only) Four screws Dome Washer Hex Tap 4x20 -2 per side (KP-51WS520/57WS520 Only)

1-11-1. SCREEN TAPE METHOD
The following demonstrates the taping method when replacing the Contrast Screen or Diffusion Plates. For Part Numbers refer to the Miscellaneous section in the back of the manual.

1 Tape, Acetate (P2412) 25x30M

Top

Contrast Screen

2 Tape, Acetate (P2412HD) 25MMx30M

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KP-46WT520/51WS520/57WS520

1-12.SR BOARD REMOVAL
The Screen Holder does not need to be removed in order to remove the SR boards.

Sensor bracket (B)

Sensor bracket (A)

6 SR board 5 Claws

3 One screw (+BVTP 4x12) 1 Four screws (+BVTP 4x12) 2 L screen holder

4 One screw (+BVTP 4x12)

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KP-46WT520/51WS520/57WS520

WIRE DRESSING

46 Cabinet

46" HB

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KP-46WT520/51WS520/57WS520

46 Cabinet
46" HA Wire

2nd Tape Position

46 Cabinet

46" HB

46" HA

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KP-46WT520/51WS520/57WS520

51 & 57 Cabinet

51" & 57" HB

51 & 57 Cabinet

51" & 57" HB

51" & 57" HA

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KP-46WT520/51WS520/57WS520

HV Wire

HV wire

HV Wire

HV wire

KP-46WT520/51WS520/57WS520

20

KP-46WT520/51WS520/57WS520

HV/MV Wire

HV/MV wire

VM Connect

VM wire

KP-46WT520/51WS520/57WS520

21

KP-46WT520/51WS520/57WS520

PWB Block Docking

PWB Block Docking

HA Connect

SP Connect

HB Connect

KP-46WT520/51WS520/57WS520

22

KP-46WT520/51WS520/57WS520

C, FP Connect

BG-

R

G

B

VM

RGB signal wire

46 DY

46" DY wire
Into the 1st purselock

VM,RGB C/N
V DY-B DY-G DY-R

KP-46WT520/51WS520/57WS520

23

KP-46WT520/51WS520/57WS520

51 & 57 DY

51" & 57"DY wire dressing

Into the free purselock (8dia)

Into the 2nd purselock

VM,RGB C/N

V DY-R DY-G DY-B

DY

H
DY-B DY-G DY-R

KP-46WT520/51WS520/57WS520

24

KP-46WT520/51WS520/57WS520

DY

Sub
DY-B DY-G

DY

Excess wire

KP-46WT520/51WS520/57WS520

25

KP-46WT520/51WS520/57WS520

Terminal Bracket Assy

ANT SW 5v C/N

Sub TU PP HB C/N

Main TU PP ANT SW GND

KP-46WT520/51WS520/57WS520

26

KP-46WT520/51WS520/57WS520

F.P

51" & 57" F.P Wire Dressing

51 & 57 V2 Block Assy
51" & 57" V2 BLK

2nd-Assy V2 BLK Test Up(lock)/Dow

1st-Assy

KP-46WT520/51WS520/57WS520

27

KP-46WT520/51WS520/57WS520

AR Sensor

46" & 51"AR Sensor Wire

AR Sensor

57" AR Sensor Wire

Excess Wire

KP-46WT520/51WS520/57WS520

28

KP-46WT520/51WS520/57WS520

AR Sensor

Excess Wire

AR Sensor

KP-46WT520/51WS520/57WS520

29

KP-46WT520/51WS520/57WS520

AR Sensor

46 V2 Assy

HB Wire Connection

KP-46WT520/51WS520/57WS520

30

KP-46WT520/51WS520/57WS520

SECTION 2: SET-UP ADJUSTMENTS 2-3. DEFLECTION YOKE TILT ADJUSTMENT
1. Connect the color bar generator monoscope pattern to Video 1 input. 2. Cover the red and blue CRT lenses with lens caps to allow only green to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps). 3. Loosen the CRT's deflection yoke set screw and align the tilt of the deflection yoke so that the horizontal bars at the center of the cross-hatch pattern are parallel to the top and bottom edges of the screen. 4. After aligning the deflection yoke fasten it securely to the funnel-shaped portion (neck) of the CRT. 5. Cover the green and blue CRT lenses with lens caps to allow only green to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps), then repeat steps 3 and 4 for the red CRT. Cover the green and red CRT lenses with lens caps to allow only green to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps), then repeat steps 3 and 4 for the blue CRT. Note: If lens caps are unavailable, you can cut off the unnecessary color beams by controlling the service mode MCP-RON, GON, BON. 4-pole magnet 2-pole magnet Deflection yoke

2-1. SCREEN VOLTAGE ADJUSTMENT (G2) (COARSE ADJUSTMENT)
1. Receive the Monoscope signal. 2. Set BRIGHTNESS to 50% and PICTURE to minimum. 3. Turn the red VR on the focus block all the way to the left and then gradually turn it to the right until the retrace line is barely visible. 4. Gradually turn the control to the left until the retrace line disappears.

R

G

B

SCREEN R G B FOCUS

FOCUS Block

2-2. SCREEN (G2) ADJUSTMENT (FINE ADJUSTMENT)
If the jig described below is available, it is recommended that the G2 Fine Mode Adjustment be performed to set the screen controls to their optimal condition. If desired, you can build the jig illustrated below, using 3-watt resistors. Please note that if the proper voltage is not obtained with the listed resistor's values, then increase or decrease one of the values in the resistor network to obtain the correct voltage. 1. Select VIDEO-1 mode no signal applied (the screen must be black). 2. Connect the G2 JIG. 3. SW on JIG. 4. Connect an oscilloscope to the TP9101(KR), TP9201(KG) and TP9301(KB) of CR board, CG board, and CB board. 5. Adjust red, green, and blue screen voltage to 177.5+/-0.5V with screen VR on the focus block.
K G2 JIG TO CG BOARD TP9202 (210V) 3.3k SW 5.6k 5.6k 6.8k GND All resistors are 3W type

Centering magnet Anode cap

177.5V +/- 0.5V GND

pedestal level

KP-46WT520/51WS520/57WS520

31

KP-46WT520/51WS520/57WS520

2-4. FOCUS LENS ADJUSTMENT
In this adjustment, use the remote commander while in service mode. For details on the usage of the service mode and the remote commander, please refer to section 2-10. ELECTRICAL ADJUSTMENTS BY REMOTE COMMANDER. 1. Loosen the lens screw. 2. Cover the red and blue CRT lenses with lens caps to allow only green to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps). 3. Turn the green lens to adjust to the optimum focus point with the crosshatch signal. 4. Tighten the lens screw. 5. Cover the green and blue CRT lenses with the lens caps to allow only red to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps). 6. Turn the red lens to adjust to the optimum focus point with the crosshatch signal. 7. Tighten the lens screw. 8. Cover the green and red CRT lenses with the lens caps to allow only blue to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps). 9. Turn the blue lens to adjust to the optimum focus point with the crosshatch signal. 10. Tighten the lens screw. 11. After adjusting the items: 2-5. FOCUS VR ADJUSTMENT, 2-7. 2-POLE MAGNET ADJUSTMENT, 2-8. 4-POLE MAGNET ADJUSTMENT, reconfirm the optimum focus point and adjust again if necessary. * In PJE mode, every time 6 is pressed, the test signal changes to: "crosshatch+video signal" "crosshatch+borderline (black)" "crosshatch (black)" "dots (black)" "all white" off

2-5. FOCUS VR ADJUSTMENT
1. Set generator to crosshatch. 2. Cover the red and blue CRT lenses with lens caps to allow only green to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps). 3. Turn the green focus VR on the focus block to adjust to the optimum focus point with the crosshatch signal. 4. Cover the green and blue picture lenses with lens caps to allow only red to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps). 5. Turn the red focus VR on the focus block to adjust to the optimum focus point with the crosshatch signal. 6. Cover the green and red picture lenses with lens caps to allow only blue to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps). 7. Turn the blue focus VR on the focus block to adjust to the optimum focus point with the crosshatch signal. 8. After adjusting the items: 2-4. FOCUS LENS ADJUSTMENT, 2-7. 2-POLE MAGNET ADJUSTMENT, 2-8. 4-POLE MAGNET ADJUSTMENT, reconfirm the optimum focus point and adjust again if necessary. Note: If lens caps are unavailable, you can cut off the unnecessary color beams by controlling the service mode MCP-RON, GON, BON.

R R

G

B

SCREEN G B FOCUS

FOCUS Block

Test Signal

Scanning line visible.

A Minimize both A and B. B

Lens

Center of crosshatch

Note: If lens caps are unavailable, you can cut off the unnecessary color beams by controlling the service mode MCP-RON, GON, BON.

KP-46WT520/51WS520/57WS520

32

KP-46WT520/51WS520/57WS520

2-6. CENTERING MAGNET ADJUSTMENT
1. Set the mode to PRO. 2. Receive the monoscope signal. 3. Cover the red and blue CRT lenses with lens caps to allow only green to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps). 4. Adjust the green CRT's centering magnet to put the center of the monoscope signal to the center of the screen. 5. Repeat steps 1 through 4 for the red CRT except now you will cover the green and blue CRT lenses with lens caps to allow only red to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps) and you will adjust the red centering magnet. 6. Repeat steps 1 through 4 for the blue CRT except now you will cover the red and green CRT lenses with lens caps to allow only blue to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps) and you will adjust the blue centering magnet. 7. After 2-Pole and 4-Pole adjustment, entering magnet adjustment needs to be confirmed. If centering magnet is re-adjusted, then 2-Pole magnet will need to be confirmed. Note: If lens caps are unavailable, you can cut off the unnecessary color beams by controlling the service mode MCP-RON, GON, BON.

2-8. 4-POLE MAGNET ADJUSTMENT
1. Set the mode to VIVID and WIDE mode = Zoom, VM:Off. 2. Receive the 100IRE 1080i Dot signal. 3. Cover the red and blue CRT lenses with lens caps to allow only green to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps). 4. Turn the (green) focus VR on the focus block to the right (clockwise) and set it to under-focus to reduce the spot. 5. Adjust the 4-pole magnet so that the small spot in the center of the screen becomes round for green and red. 6. Adjust the blue spot for: a. KP-46WT520/51WS520 to a round shape X:Y=1:1 b. KP-57WS520 to an oval shape X:Y=1.2:1 7. Repeat steps 1 through 6 for the red CRT except now you will cover the green and blue CRT lenses with lens caps to allow only red to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps) and you will adjust the red focus control on the focus block. 8. Repeat steps 1 through 6 for the blue CRT except now you will cover the red and green CRT lenses with lens caps to allow only blue to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps) and you will adjust the blue focus control on the focus block. Note: If lens caps are unavailable, you can cut off the unnecessary color beams by controlling the service mode MCP-RON, GON, BON.
Use the center dot
x y x : y = 1:1 (Green, Red)

2-7. 2-POLE MAGNET ADJUSTMENT
1. Set the mode to PRO and picture to MAX. 2. Receive the 100IRE 1080i Dot signal. 3. Cover the red and blue CRT lenses with lens caps to allow only green to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps). 4. Turn the focus VR on the focus block to the left (counter clockwise) and set it to overfocus to enlarge the spot. 5. Adjust the CRT's 2-pole magnet so that the small bright spot is in the center. 6. Align the focus VR on the focus block and set it for the best focus. 7. Repeat steps 1 through 6 for the red CRT covering the green and blue CRT lenses with lens caps to allow only red to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps) and you will adjust the red focus control on the focus block. 8. Repeat steps 1 through 6 for the blue CRT covering the red and green CRT lenses with lens caps to allow only blue to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps) and you will adjust the blue focus control on the focus block. Note: If lens caps are unavailable, you can cut off the unnecessary color beams by controlling the service mode MCP-RON, GON, BON.

2-9. DEFOCUS ADJUSTMENT (BLUE)
Note: Adjust the blue dot to be slightly larger than red and green dots. This adjustment provides a more pleasing picture to the customer. 1. Set the mode to PRO, PICTURE : Max, COLOR TEMP : Cool. 2. Receive the 100IRE 1080i Dot signal. 3. Cover the red and green CRT lenses with lens caps to allow only blue to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps). 4. Turn the blue focus VR on the focus block to the right (clockwise) until blue spot is in focus. 5. Change mode to VIVID to confirm Flare level is minimal using cross hatch signal. 6. Set the generator to an all white signal and check uniformity. Note: If lens caps are unavailable, you can cut off the unnecessary color beams by controlling the service mode MCP-RON, GON, BON.

Adjust Point

KP-46WT520/51WS520/57WS520

33

KP-46WT520/51WS520/57WS520

2-10.ELECTRICAL ADJUSTMENTS BY REMOTE COMMANDER
All of the circuit adjustments can be made by using the remote commander (RM-Y916). Note: The following test equipment is required: 1. Pattern Generator (with component outputs) 2. Frequency counter 3. Digital multimeter 4. Audio oscillator

7. If you want to go back to the most recently saved value, press "0" then "ENTER" to read the memory. 8. Press "MUTING" then "ENTER" to write the new adjustment data into memory. 9. Turn power off when you want to exit the service mode. Note:: Press "8" then "ENTER" on the remote commander to restore the factory settings for user controls and channel memories (this will also turn set off and then on to exit the service mode).

2-10-2. MEMORY WRITE CONFIRMATION METHOD
1. After adjustment, turn the power off with the remote commander. 2. Turn the power ON and set to service mode. 3. Cycle through the adjusted items again and confirm that the adjustments were saved.

2-10-1. METHOD OF ENTERING THE SERVICE ADJUSTMENT MODE
SERVICE MODE PROCEDURE 1. TV must be in Standby mode. (Power off) 2. Press "DISPLAY", "5", "VOL +", then "POWER" on the remote commander. (Press each button within 1 second of pressing the previous button.) SERVICE MODE ADJUSTMENT
Item NO. Category Data

2-10-3. ADJUSTING BUTTONS AND INDICATOR
Note: When the PJE mode (which displays an internally generated signal) is activated, several buttons on the remote commander will have different functions than the ones listed below. Therefore, when in the PJE mode, refer to section 2-12-3 for button functions. WIDE MODE DISPLAY POWER TV/VIDEO Data up Data down Category down ENTER

Adjustment Item

3D-COMB 0 0 SERVICE TV NRMD WSL : XXX F / A FLAG : XXXXXXXX CBA FLAG : XXXXXXXX

MUTING PICTURE Category up Adjustment item up Adjustment item down Test Reset

3. 4. 5. 6.

The screen displays the item being adjusted within that category. Press 1 or 4 on the remote commander to select the adjustment item Press 3 or 6 on the remote commander to change the data Press 2 or 5 on the remote commander to select the adjustment category Every time you press 2 (Category up), service mode changes in the order shown below:

RNR VERSION USER LUMA COLR CLTY MIDE CCPM COMB YCTS MCP DEF1 BNR DEF2 SNNR DEF3 AWID DEF4 DDEV DEF5 MID1 MID2 MID3 VSW CRNR PJED FDIS PJED CENT PJED V1CM AP PJED OTVS MSMO PJED AIVP OSDP PJED A1SV ASEL PJED DFHG PJED VUP PJED ROGH PJED SFTF PJED PV3P

VSEL DRCV PFID PFOP OP ATSC ID

ANT

VOLUME

RM-Y916

KP-46WT520/51WS520/57WS520

34

KP-46WT520/51WS520/57WS520

2-11.ADJUSTABLE SERVICE DATA LISTS
Only the Adjustable registers are shown in this data list. A complete set of the service data, Fixed and Adjustable, can be downloaded at: http://www-ec.sdp.sel.sony.com/padics/Model_Data_List.htm Only Sony authorized Service Technician can access this site.

SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY OP

# 5 6

ITEM OSDH OSDF

DESCRIPTION OSD Horizontal Position OSD Favorite Position

CONDITION (common) (common)

21 28

21 28

21 28

0 0

255 63

SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY CCPM

# 1 2 3

ITEM YLEV CLEV SHUE SCON SCOL SHUE CBOF CROF VPOS VSIZ HSIZ SLIN RDRV BDRV RCUT BCUT SBRT

DESCRIPTION Y Level C Level Sub Hue Sub Contrast Sub Color Sub Hue Cb Offset Cr Offset Vertical Position Vertical Size Horizontal Size S Linearity Red Drive Gain Blue Drive Gain Red cut-off Blue cut-off Sub Bright

CONDITION RF - 60HZ CV - 60HZ RF - 60HZ CV - 60HZ RF - 60HZ CV - 60HZ RF OTHER RF OTHER RF OTHER DRC - RF/BS/CV/YC DRC - RF/BS/CV/YC COMMON COMMON WIDEZOOM OTHER WIDEZOOM OTHER COMMON COMMON COMMON COMMON COMMON

205 190 110 103 7 7 9 6 6 5 3 5 31 30 25 31 24 24 7 7 38 23 23 27 23

205 190 110 103 7 7 9 6 6 5 3 5 31 30 25 31 24 24 7 7 38 23 23 27 23

205 190 110 103 7 7 9 6 6 5 3 5 31 30 25 31 24 24 7 7 38 23 23 27 23

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

255 255 255 255 15 15 15 15 15 15 15 15 63 63 63 63 63 63 15 15 63 63 63 63 63

YCTS (CXA2103)

2 3 4

MCP DEF1 DEF2

9 10 0 1 2 3

COLR

2 4 5 7 8

KP-46WT520/51WS520/57WS520

MAX

MIN

MAX

MIN

35

KP-46WT520/51WS520/57WS520

SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY PJE

# 93 94 95 96 97 98 99

ITEM R0GH R0RH R0BH R1GH R1RH R1BH R2GH

DESCRIPTION Ratio Offset S0 G H Ratio Offset S0 R H Ratio Offset S0 B H Ratio Offset S1 G H Ratio Offset S1 R H Ratio Offset S1 B H Ratio Offset S2 G H Ratio Offset S2 R H Ratio Offset S2 B H Ratio Offset S3 G H Ratio Offset S3 R H Ratio Offset S3 B H Ratio Offset S1 G V Ratio Offset S1 R V Ratio Offset S1 B V Ratio Offset S2 G V Ratio Offset S2 R V Ratio Offset S2 B V Pattern Offset Top R H Pattern Offset Top B H Pattern Offset Left R H Pattern Offset Left B H Pattern Offset Left R V Pattern Offset Left B V Pattern Offset Right R H Pattern Offset Right B H Pattern Offset Right G V Pattern Offset Right R V Pattern Offset Right B V Pattern Offset Bottom G H Pattern Offset Bottom R H Pattern Offset Bottom B H Auto Regi Error Code Auto Regi V Upper Pattern Position Auto Regi V Middle Pattern Position Auto Regi V Lower Pattern Position Auto Regi H Left Pattern Position Auto Regi H Middle Pattern Position Auto Regi H Right Pattern Position

CONDITION (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common) (common)

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 50 495 947 181 853 1522

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 50 495 947 181 853 1522

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 50 495 947 181 853 1522

-128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 -128 0 0 0 0 0 0 0

127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 127 255 2047 2047 2047 2047 2047 2047

100 R2RH 101 R2BH 102 R3GH 103 R3RH 104 R3BH 105 R1GV 106 R1RV 107 R1BV 108 R2GV 109 R2RV 110 R2BV 111 PTRH 112 PTBH 113 PLRH 114 PLBH 115 PLRV 116 PLBV 117 PRRH 118 PRBH 119 PRGV 120 PRRV 121 PRBV 122 PBGH 123 PBRH 124 PBBH 125 ERR 130 VUP 131 VMID 132 VLOW 133 HLE 134 HMID 135 HRIT

KP-46WT520/51WS520/57WS520

MAX

MIN

36

KP-46WT520/51WS520/57WS520

SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY PJE

#

ITEM

DESCRIPTION R H Cent

CONDITION Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

141 CENT

40 40 40 40 40 40 20 20 20 20 20 20 40 40 40 40 40 40 20 20 20 20 20 20

40 40 40 40 40 40 20 20 20 20 20 20 40 40 40 40 40 40 20 20 20 20 20 20

40 40 40 40 40 40 20 20 20 20 20 20 40 40 40 40 40 40 20 20 20 20 20 20

-512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512

511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511

R V Cent

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

G H Cent

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

G V Cent

Full / Normal Zoom WideZoom 1080i Full 1080i Zoom 1080i WideZoom

KP-46WT520/51WS520/57WS520

MAX

MIN

37

KP-46WT520/51WS520/57WS520

SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY PJE

# 141

ITEM

DESCRIPTION B H Cent

CONDITION Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

40 40 40 40 40 40 20 20 20 20 20 20 -120 -120 -120 -120 -120 -120 -80 -80 -80 -80 -80 -80

40 40 40 40 40 40 20 20 20 20 20 20 -120 -120 -120 -120 -120 -120 -80 -80 -80 -80 -80 -80

40 40 40 40 40 40 20 20 20 20 20 20 -120 -120 -120 -120 -120 -120 -80 -80 -80 -80 -80 -80

-512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512

511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511

B V Cent

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

142 SIZE

R H Size

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

R V Size

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

KP-46WT520/51WS520/57WS520

MAX

MIN

38

KP-46WT520/51WS520/57WS520

SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY PJE

#

ITEM

DESCRIPTION G H Size

CONDITION Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

142 SIZE

-120 -120 -120 -120 -120 -120 -80 -80 -80 -80 -80 -80 -120 -120 -120 -120 -120 -120 -80 -80 -80 -80 -80 -80

-120 -120 -120 -120 -120 -120 -80 -80 -80 -80 -80 -80 -120 -120 -120 -120 -120 -120 -80 -80 -80 -80 -80 -80

-120 -120 -120 -120 -120 -120 -80 -80 -80 -80 -80 -80 -120 -120 -120 -120 -120 -120 -80 -80 -80 -80 -80 -80

-512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512

511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511

G V Size

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

B H Size

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

B V Size

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

KP-46WT520/51WS520/57WS520

MAX

MIN

39

KP-46WT520/51WS520/57WS520

SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY PJE

#

ITEM

DESCRIPTION R H Lin

CONDITION Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

143 LIN

300 300 300 300 300 300 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

300 300 300 300 300 300 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

300 300 300 300 300 300 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

-512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512

511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511

R V Lin

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

G H Lin

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

G V Lin

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

KP-46WT520/51WS520/57WS520

MAX

MIN

40

KP-46WT520/51WS520/57WS520

SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY PJE

#

ITEM

DESCRIPTION B H Lin

CONDITION Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

143 LIN

-300 -300 -300 -300 -300 -300 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

-300 -300 -300 -300 -300 -300 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

-300 -300 -300 -300 -300 -300 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

-512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512

511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511

B V Lin

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

144 SKEW

R H Skew

Full / Normal Zoom WideZoom 1080i Full 1080i Zoom 1080i WideZoom

R V Skew

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

KP-46WT520/51WS520/57WS520

MAX

MIN

41

KP-46WT520/51WS520/57WS520

SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY PJE

#

ITEM

DESCRIPTION G H Skew

CONDITION Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

144 SKEW

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

-512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512

511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511

G V Skew

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

B H Skew

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

B V Skew

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

KP-46WT520/51WS520/57WS520

MAX

MIN

42

KP-46WT520/51WS520/57WS520

SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY PJE

#

ITEM

DESCRIPTION R H Bow

CONDITION Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

145 BOW

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

-512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512

511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511

R V Bow

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

G H Bow

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

G V Bow

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

KP-46WT520/51WS520/57WS520

MAX

MIN

43

KP-46WT520/51WS520/57WS520

SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY PJE

#

ITEM

DESCRIPTION B H Bow

CONDITION Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

145 BOW

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 130 130 130 130 130 130

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 130 130 130 130 130 130

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 130 130 130 130 130 130

-512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512

511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511

B V Bow

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

146 KEY

R H Key

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

R V Key

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

KP-46WT520/51WS520/57WS520

MAX

MIN

44

KP-46WT520/51WS520/57WS520

SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY PJE

#

ITEM

DESCRIPTION G H Key

CONDITION Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

146 KEY

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -130 -130 -130 -130 -130 -130

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -130 -130 -130 -130 -130 -130

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -130 -130 -130 -130 -130 -130

-512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512

511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511

G V Key

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

B H Key

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

B V Key

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

KP-46WT520/51WS520/57WS520

MAX

MIN

45

KP-46WT520/51WS520/57WS520

SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY PJE

#

ITEM

DESCRIPTION R H Pin

CONDITION Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

147 PIN

0 0 0 0 0 0 380 380 380 380 380 380 0 0 0 0 0 0 430 430 430 430 430 430

0 0 0 0 0 0 380 380 380 380 380 380 0 0 0 0 0 0 430 430 430 430 430 430

0 0 0 0 0 0 380 380 380 380 380 380 0 0 0 0 0 0 430 430 430 430 430 430

-512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512

511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511

R V Pin

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

G H Pin

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

G V Pin

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

KP-46WT520/51WS520/57WS520

MAX

MIN

46

KP-46WT520/51WS520/57WS520

SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY PJE

#

ITEM

DESCRIPTION B H Pin

CONDITION Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

147 PIN

0 0 0 0 0 0 380 380 380 380 380 380 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 380 380 380 380 380 380 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 380 380 380 380 380 380 0 0 0 0 0 0 0 0 0 0 0 0

-512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512

511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511

B V Pin

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

148 MLIN

R H Middle Lin

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

G H Middle Lin

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

KP-46WT520/51WS520/57WS520

MAX

MIN

47

KP-46WT520/51WS520/57WS520

SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY PJE

#

ITEM

DESCRIPTION B H Middle Lin

CONDITION Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

148 MLIN

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

-512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512 -512

511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511 511

149 MSIZ

R H Middle Size

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

G H Middle Size

Full / Normal Zoom WideZoom 1080i Full / Normal 1080i Zoom 1080i WideZoom

B H Middle Size

Full / Normal Zoom / V.Comp WideZoom 1080i Full 1080i Full 1080i V.Comp

KP-46WT520/51WS520/57WS520

MAX

MIN

48

KP-46WT520/51WS520/57WS520

2-11-1. ID MAP TABLE
SERVICE DATA (dec)

51WS520 (U/C)

57WS520 (U/C)

46WT520 (U/C)

CATEGORY ID

# 0 1 2 3 4 5 6 7

ITEM ID0 ID1 ID2 ID3 ID4 ID5 ID6 ID7

DESCRIPTION ID Byte 0 ID Byte 1 ID Byte 2 ID Byte 3 ID Byte 4 ID Byte 5 ID Byte 6 ID Byte 7

CONDITION (common) (common) (common) (common) (common) (common) (common) (common)

89 255 239 106 75 243 190 155

89 255 239 106 75 243 190 155

89 255 239 106 75 243 190 155

0 0 0 0 0 0 0 0

255 255 255 255 255 255 255 255

KP-46WT520/51WS520/57WS520

MAX

MIN

49

KP-46WT520/51WS520/57WS520

2-12.REGISTRATION ADJUSTMENT (PJE MODE ONLY)
*ADJUSTING FLOW START

2-12-1. SETUP FOR ADJUSTMENT
MARKING · At the 4 sides of the screen, locate the middle. Use a tape measure to identify the middle.

Turn on the power and wait for 10 minutes.

Set to the NTSC Full mode

: middle DATA SETTING 1. Set NTSC Full mode. 2. Enter the service mode, and select "PJE".

Check the deflection yokes, the centering magnets, 2 pole/4 pole magnets

Set to the service mode.

2-12-2. MAIN DEFLECTION ADJUSTMENT
MAIN DEFLECTION ADJUSTMENT (Green) Green coarse adjustment

NOTE: Before this adjustment, refer to section 2-11 SERVICE DATA LISTS for PJE item #141-149 input data. 1. Cover the red and blue CRT lenses with lens caps to allow only green to show (or use the method shown in the note below for turning off the CRTs individually without using lens caps). 2. Enter the monoscope signal and set to NTSC Full mode. 3. Enter the service mode, and select "DEF1". 4. Adjust "0 VPOS" and "1 VSIZ" so that the picture is displayed in the center of the screen. 0 VPOS

Green fine adjustment

Red coarse adjustment SUB DEFLECTION ADJUSTMENT

***

Change the wide screen mode

Red fine adjustment

Blue coarse adjustment

Blue fine adjustment

Yes

Another wide screen mode? No

1 V-Size

Memorize the FLASH FOCUS offset data (Run flash focus in PJE Service Mode)

5. Select "DEF2" and adjust "2 H-Size" so that the picture size is within the specification. SPEC Overscan Spec. = 9% H SIZE 15.6 ± 0.2 sq. V SIZE 11.5 ± 0.2 sq.

End *** COPY When the NTSC Full mode adjustment has finished, copy its data to NTSC Zoom, HD Full, and HD Zoom modes the first time only and be sure to adjust in the order given. When the NTSC Wide Zoom mode adjustment has finished, copy its data to HD Wide Zoom mode. This will serve as a starting point for adjusting these other modes. See section 2-13-2. Copying All Registration Data To Other Modes for more information.

Input Signal Monoscope 2 H-Size

6. Copy the data of the NTSC Full mode to the other wide screen mode and, if necessary, adjust in the other mode.

KP-46WT520/51WS520/57WS520

50

KP-46WT520/51WS520/57WS520

2-12-3. OPERATION METHOD FOR PROJECTOR ENGINE MODE
DISPLAY MUTING Category up Adjustment item up Adjustment item down Category down Initialize data (Not stored) Test Reset MENU POWER Color Select GRN to BLU to RED Test signal select crosshatch + video signal dots + video signal crosshatch + black dots and black off Mode Select (Course Adjustment Fine Adjustment) ENTER

Press Switches marker moving method. Joystick (In Fine Adjustment mode) Pressing down on the joystick in Fine Adjustment mode switches between selecting and un-selecting a point. When a point is selected, the cursor changes to that color to indicate the point is selected and can be adjusted. If a point is not selected the cursor is white. Joystick 5 6 3 4 keys 1 and 4 buttons Commander Function Buttons Mode 0 + ENTER READ MUTING+ENTER WRITE 7 + ENTER PJE INITIAL Description Reads data to NVM. Writes data from NVM. Service data initialization. Not stored. (Be sure not to use usually)

2. OPERATION METHOD FOR COARSE ADJUSTMENT 1. Enter the service mode and select "PJE". 2. Press the "1" or "4" button on the remote commander to select the item, and then use the joystick to change the data. Item No. RM-Y916 1. FUNCTION OF KEYS ON COMMANDER 1 Changes adjustment item. (Item # moves up) Marker moves clockwise from center to outside. (In Fine Adjustment mode) 4 Changes adjustment item. (Item # moves down) Marker moves counter clockwise from outside to center. (In Fine Adjustment mode) 2 Changes adjustment category. (Category # moves up) 5 Changes adjustment category. (Category # moves down) Joystick Changes data value. (Up or down) Marker moves clockwise from center (up, down, right, and then left) to outside. (In Fine Adjustment mode) 3 Changes adjustment color. GRN BLU RED 6 Displays or changes internal test signals. crosshatch + external signal crosshatch + borderline crosshatch only dot only off 9 Switches adjustment mode. Coarse adjustment model Fine adjustment point mode Fine adjustment row mode Fine adjustment column mode Data 00 60

PJE FDIS

00

Joystick Adjustment Item 54 direction:Data up 63direction:Data down

3. Select "GRN CENT". When BLU or RED is displayed, press the "3" button on the remote commander to change the adjustment color in the order of GRN BLU RED. 4. In the GRN, BLU, or RED mode, move the joystick 5 or 6to change the data in vertical direction, or 3 or 4 to change the data in a horizontal direction. Color Data (H) Data (V)

GRN CENT

000

000

60

Adjustment Item

3 : Data (H) up 4 : Data (H) down 5 : Data (V) up 6 : Data (V) down

5. Before returning to the service mode, press the "MUTING" + "ENTER" buttons on the remote commander to write the data. (You must complete step 5 to write the data. If you omit step 5 the set data is returned to the data prior to the adjustment.)

KP-46WT520/51WS520/57WS520

51

KP-46WT520/51WS520/57WS520
3. OPERATION METHOD FOR FINE ADJUSTMENT 1. Enter the service mode and select "PJE". 2. Select FDIS and set the data to "01" so that the data at each position can be displayed in fine adjustment mode. 3. Press the "9" button on the remote commander and fine adjustment mode will be active where a green marker appears in the center of the screen. (In the case of GRN mode) 4. Press down on the joystick, and the marker color will be alternately switched between green (GRN mode) and white. 5. Press the "1" or "4" button on the remot